Burning smell from new Rear Brake Disc

**muchos04** · 21-09-2009,12:19 PM

Hi Guys,

Hope somebody can help me with this query. I replaced my rear brake discs and pads at the weekend. I pushed the calliper pistons back in with the rewind tool but noticed that the dust glove was practically gone from the piston. However, I continued with great effort to rewind the piston back in and fitted the disc and pads.

On the other side I did the same but here the piston dust glove appeared intact but I am getting a burning smell on this side. When I did a few high effort stops and looked at the wheel there was smoke coming from it. I did spray WD40 on the guide pins to free them up and everything else I used copper grease.

Is there anything to worry about or will this go away. The disc always seems to be much hotter than the other one after a run. Any ideas as to what might be the problem would be greatlyt appreciated!

Regards, Muchos04

**zollaf** · 21-09-2009,12:41 PM

jack up both rear wheels clear of the ground. release the handbrake and make sure the wheels spin freely. then apply the footbrake hard and again make sure both wheels spin freely, when released. if either doesnt spin freely, youve found the problem. it does sound like a partially seized caliper, or could be a sticky handbrake. if it binds when the hb is released, try pulling the actuating lever on the caliper.

**muchos04** · 21-09-2009,01:00 PM

Thanks very much for the quick reply Zollaf. When you say pull the caliper lever, is this the lever which the handbrake wire is connected to? Would you recommend I fix the dust glove on the other caliper or should this be left alone?

Regards
Muchos04

**Crasher** · 21-09-2009,01:24 PM

You need to replace the caliper that had the seal missing and it is normally the right hand side, but don’t ask me why because I don’t know! Check the guide pins move freely. Don’t forget that if you disconnect the caliper from the hose you must replace the complete hose/pipe as it has a one time only seal.

**muchos04** · 21-09-2009,02:55 PM

Cheers Crasher,

Do you think I'd get away with ordering a caliper repair kit and putting new seals on?

Regards
Dave

**Crasher** · 21-09-2009,04:32 PM

Possibly, as long as the piston is not pitted by corrosion.

**muchos04** · 24-09-2009,09:31 AM

Hi Guys,
Is it possible to fit a new dust glove without taking apart the caliper?

Regards
Muchos04

**NickPicks** · 24-09-2009,09:57 AM

It's possible, but if you're replacing the dust cap, then presumably it's because the old one is split and leting in dust. If you just put a new one on without doing the rest, then you'll only be sealing in the dust.

It's not that difficult to take the caliper off, replace all the seals, refit it and bleed the brakes.

If you do it properly, you'll be able to feel satisfied in the knowledge that you've done a good job (on both sides), rather than always thinking "I wonder if that brake caliper that I bodged back together is going to stop this car before I run out of road and end up in a ditch".

**muchos04** · 24-09-2009,10:22 AM

Many thanks for your quick reply NickPicks!
Would you know of any links to instructions on how to take off the caliper and dissassemble? I have been looking everywhere and cannot find one for a VW Golf or similar?

Regards
Muchos04

**NickPicks** · 24-09-2009,11:26 AM

Can you get hold of a workshop manual? The best one you can get is the Bentley manual, which I think is quite expensive. The Haynes manuals in the UK arean't as good, but should be enough for calliper removal and overhaul.